Support mechanism for holding a component in a component rack and a method of manufacture therefor

ABSTRACT

The present invention provides a support mechanism for holding a component in a component rack, a method of manufacture therefor, and a rack of components. The support mechanism, among other elements, may include a shelf configured to hold a component, the shelf having a sidewall with at least two slots therein extending from the sidewall and the shelf. The support mechanism may further included a mounting flange coupleable to the shelf, the mounting flange having at least two tabs configured to engage the at least two slots.

TECHNICAL FIELD OF THE INVENTION

The present invention is directed, in general, to a support structure and, more specifically, to a support mechanism for holding a component in a component rack, a method of manufacture therefor, and a rack of components.

BACKGROUND OF THE INVENTION

The myriad of cooperating electrical components available today has created a need for apparatus which can securely and effectively store these components in stacked relationship, not only so that the components can be electrically interconnected with one another, but so that they can be readily accessed and used. This is particularly true in power management situations in which a large number of individual components are typically used together in order to create a desired power management system.

This need has led manufacturers to standardize the width dimension of rack mounting systems that may house these components. Such systems generally consist of some sort of frame structure to which a pair of rack rails are fixedly mounted at an appropriate distance from one another for accepting shelves supporting the components or the components themselves. Each shelf is then mounted to the rack rails by aligning a pair of apertures or slots on each side of its front face with corresponding apertures in the rack rails and by using bolts or other such fasteners to complete the assembly. These rack mounting systems are extant both in the form of rather large open systems permanently installed in establishments, and in the form of relatively small boxes which fully enclose the shelves of components to protect same from damage due to the surroundings.

Over the course of many years, as well as many design iterations, the industry has attempted to optimize these rack mounting systems, and particularly the mechanism for fixedly mounting the shelf to the rack rails. Original designs had ears, having apertures or slots therein for fastening the shelf to the rack rails, integrally formed directly into the shelf itself. However, the industry soon realized that any serious malfunction of the ears themselves would require discarding the entire shelf.

The industry then turned to flanges that could be removable mounted to a sidewall of the shelf itself, wherein the flange then had the ear having apertures or slots therein for fastening the shelf to the rack rails. If the flange itself were to malfunction, it could be removed and a new flange could be installed in its place. Accordingly, the shelves were rarely discarded.

Turning briefly to prior art FIG. 1, illustrated is one mounting system 100 designed such that a flange 110 may be removably mounted to a shelf 120 using a screw 130 and nut 140. As is shown, the screw 130 extends initially through the flange 110, then through the shelf 120, wherein it encounters the nut 140, thereby rigidly, but removably, mounting the flange 110 to the shelf 120. Unfortunately, this technique for removably mounting the flange 110 to the shelf 120 has certain design defects. One design defect is the inability to easily fix the threads on the nut 140 if they are damaged. Another design defect is the valuable shelf space that it takes up. For instance, this technique reduces the shelf space by a distance X₁, wherein the distance X₁ consists of the thickness of the flange 110, thickness of the shelf 120, thickness of the nut 140, at least two safety threads of the screw 130 and any desired clearance. Accordingly, to continue using standardized racks and accommodate this reduction in shelf space X₁, the components themselves would have to be reduced in size.

Turning now briefly to prior art FIG. 2, illustrated is another mounting system 200 designed such that a flange 210 may be removably mounted to a shelf 220 using a screw 230 and nut 240. As is shown, this time the screw 130 extends initially through the shelf 220, then through the flange 210, wherein it encounters the nut 240, thereby rigidly, but removably, mounting the flange 210 to the shelf 220. Unfortunately, this technique for removably mounting the flange 210 to the shelf 220 also has certain design defects. The major design defect is again the valuable shelf space that the mounting system 200 takes up. For instance, the use of this technique reduces the shelf space by a distance X₂, wherein the distance X₂ consists of the desired clearance, the thickness of the shelf 220, the thick thickness of the flange 210, the thickness of the nut 240 and at least two safety threads of the screw 230. Accordingly, to continue using standardized racks and accommodate this reduction in shelf space X₂, the components themselves would again have to be reduced in size.

Accordingly, what is needed in the art is a technique for mounting the flange to the shelf without experiencing the drawbacks discussed above.

SUMMARY OF THE INVENTION

To address the above-discussed deficiencies of the prior art, the present invention provides a support mechanism for holding a component in a component rack, a method of manufacture therefor, and a rack of components. The support mechanism, among other elements, may include a shelf configured to hold a component, the shelf having a sidewall with at least two slots therein extending from the sidewall and the shelf. The support mechanism may further included a mounting flange coupleable to the shelf, the mounting flange having at least two tabs configured to engage the at least two slots. Another aspect of the invention is a method for manufacturing the support mechanism.

In addition to the support mechanism and method of manufacture therefor, the present invention provides the rack of components. The rack of components, without being limited to such, may include 1) a component rack, 2) a plurality of support mechanisms coupled to the component rack at vertically spaced positions, each support mechanism comprising a shelf configured to hold a component, the shelf having a sidewall with at least two slots therein extending from the sidewall and the shelf, and a mounting flange coupled to the shelf, the mounting flange having at least two tabs configured to engage the at least two slots and an ear extending substantially perpendicular to a surface that the at least two tabs are located on, and wherein the ear fastens the flange and shelf to a vertical position along the component rack, and 3) one or more components located in the support mechanisms.

The foregoing has outlined preferred and alternative features of the present invention so that those skilled in the art may better understand the detailed description of the invention that follows. Additional features of the invention will be described hereinafter that form the subject of the claims of the invention. Those skilled in the art should appreciate that they can readily use the disclosed conception and specific embodiment as a basis for designing or modifying other structures for carrying out the same purposes of the present invention. Those skilled in the art should also realize that such equivalent constructions do not depart from the spirit and scope of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention is best understood from the following detailed description when read with the accompanying FIGUREs. It is emphasized that in accordance with the standard practice in the industry, various features are not drawn to scale. In fact, the dimensions of the various features may be arbitrarily increased or reduced for clarity of discussion. Reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:

Prior Art FIG. 1 illustrates one mounting system designed such that a flange may be removably mounted to a shelf using a screw and nut;

FIG. 2 illustrates another mounting system designed such that a flange may be removably mounted to a shelf using a screw and nut;

FIG. 3 illustrates a plan view of a support mechanism for holding a component in a component rack, manufactured in accordance with the principles of the present invention;

FIG. 4 illustrates a plan view of the support mechanism illustrated in FIG. 3 as the mounting flange is coupled to the sidewall of the shelf;

FIG. 5 illustrates a sectional view of the support mechanism illustrated in FIG. 4 taken through the line 5-5; and

FIG. 6 illustrates a plan view of a rack of components manufactured and assembled in accordance with the principles of the present invention.

DETAILED DESCRIPTION

Referring initially to FIG. 3, illustrated is a plan view of a support mechanism 300 for holding a component in a component rack, manufactured in accordance with the principles of the present invention. The support mechanism 300 illustrated in FIG. 3 includes a shelf 310 configured to hold a component. The shelf 310 may be configured to hold any known or hereafter discovered components, including mechanical, electrical and other types of components. In one particular embodiment of the present invention, however, the shelf 310 is configured to hold rectifiers for use in a power management system. The present invention should, nevertheless, not be limited to such components.

The shelf 310 illustrated in the embodiment of FIG. 3 includes a sidewall 320. While the sidewall 320 is illustrated as projecting upward from a lower surface of the shelf 310, other embodiments exist wherein the sidewall 320 projects downward from an upper surface of the shelf 310. Advantageously included within the sidewall 320 are at least two slots 330. In the illustrative embodiment of FIG. 3 the at least two slots 330 extend outwardly from the sidewall 320 and the shelf 310. Another embodiment of the invention, however, exists wherein the at least two slots 330 extend inwardly from the sidewall 320 and the shelf 310. Outward and inward, as used herein, refer to away from a centerline of the shelf 310 and toward a centerline of the shelf 310, respectively. Each of the slots 330 in the embodiment of FIG. 3 may include an opening 335 through a face thereof for accepting a fastener.

The embodiment illustrated in FIG. 3 denotes that the shelf 310 may comprise only five slots 330 extending along an entire length of the sidewall 320. This embodiment should not be used to limit the present invention to an only five-slot design, and further should not be used to limit the present invention to only those designs wherein the slots 330 extend along the entire length of the sidewall 320. For example, any number of slots 320, as long as there are at least two, may be located at any position along the sidewall 320, either horizontal or vertical. One particularly advantageous embodiment, however, has the slots 330 located proximate a front face of the shelf 310, at a mid point of the shelf 310, or a combination thereof.

As further illustrated in FIG. 3, the slots 330 may have predetermined and different spacings between themselves. For instance, wherein a spacing Y_(1s) between a first slot and a second may be a first value, a spacing Y_(2s) between the second slot and a third slot may be a different value (e.g., Y_(1s)≠Y_(2s)). This configuration, as will be discussed in more detail below, allows for the fast and accurate positioning of the mounting flange 350 with respect to the shelf 310.

Those skilled in the art understand the plurality of different processes that could be used to form the slots 330 and the openings 335 in the faces thereof. Nevertheless, one particularly advantageous embodiment has the slots 330 and openings 335 formed by punching the sidewall 320. Other processes could nevertheless be used.

As previously mentioned, the support mechanism 300 further includes a mounting flange 350 coupleable to the shelf 310. The mounting flange 350, in accordance with the principles of the present invention, has at least two tabs 360 configured to engage the at least two slots 330 in the sidewall 320 of the shelf 310. In an exemplary embodiment, the at least two tabs 360 are configured to engage the at least two slots 330 and substantially fix all but one axis of movement with respect to eachother. For example, when engaged, the at least two tabs 360 only allow movement in a direction toward or away from the front face of the shelf 310. This advantageously allows a substantial portion of any forces generated between the shelf 310 and the mounting flange 350 to be focused on the structures themselves rather than any fastener used to couple the shelf 310 and the mounting flange 350 together.

In one exemplary embodiment of the present invention, each of the at least two tabs 360 contain a threaded opening 365 therein. The threaded openings 365 are configured to correspond with threads of a fastener 380. Advantageously, the fastener 380 allows the one axis of movement discussed above to be fixed. Accordingly, when the fasteners 380 engage the threaded openings 365 through the openings 335, the mounting flange 350 is secured to the shelf 310.

The embodiment illustrated in FIG. 3 denotes that the mounting flange 350 may comprise only three tabs 360. This embodiment should not be used to limit the present invention to an only three tab 360 design. For example, any number of tabs 360, as long as there are at least two, may be included within the mounting flange 350. The two most common embodiments, however, include mounting flanges 350 containing two and three tabs 360.

As further illustrated in FIG. 3, the tabs 360 may have predetermined and different spacings between themselves. For instance, wherein a spacing Y_(1f) between a first tab and a second tab may be a first value, a spacing Y_(2f) between the second tab and a third tab may be a different value (e.g., Y_(1f)≠Y_(2f)). In an exemplary embodiment, the predetermined and different spacings between the tabs 360 correspond to the predetermined and different spacings between the associated slots 330. For example, the distance Y_(1s) may equal Y_(1f) and the distance Y_(2s) may equal Y_(2f). Other embodiments also exist wherein all the distances Y_(1s), Y_(2s), Y_(1f) and Y_(2f) are the same.

The mounting flange 350 illustrated in FIG. 3 further includes an ear 370 extending substantially perpendicular to the surface that the tabs 360 are located on. The ear 370, as will be shown in later FIGUREs, is configured to fasten the mounting flange 350, and thus the shelf 310 when the mounting flange 350 is coupled to the shelf 310 using the slots 330 and tabs 360, to a vertical position along a component rack. The ear 370, as shown, includes apertures therein for making such a coupling.

Those skilled in the art understand the number of different processes that could be used to form the tabs 360 in the mounting flange 350, including conventionally stamping the tabs 360 into the mounting flange 350. In this embodiment, the tabs 360 would be flush with opposing faces of the mounting flange 350. Similarly, those skilled in the art understand the processes that may be used to create the threaded openings 365, including using a conventional tap and die set. While certain examples for forming both the tabs 360 and threaded openings 365 have been given, those skilled in the art appreciate that other processes could nevertheless be used.

The embodiment illustrated and discussed with respect to FIG. 3 contains only a single sidewall 320 and a single associated mounting flange 350. In most embodiments, however, the shelf 310 would contain two sidewalls 320 on opposing sides thereof, and two mounting flanges 360 would be configured to couple to the two sidewalls 320. Accordingly, the shelf 310 would be supported at two positions to the component rack.

Turning now to FIG. 4, illustrated is a plan view of the support mechanism 300 illustrated in FIG. 3 as the mounting flange 350 is coupled to the sidewall 320 of the shelf 310. As is illustrated in this embodiment, the tabs 360 of the mounting flange 350 are engaging the slots 330 in the shelf 310. As is further illustrated, the fasteners 380 extend through the slots 330 and into the tabs 360 to secure the one free axis of movement.

In the illustrative embodiment of FIG. 4, the mounting flange 350 is mounted substantially flush with a front surface of the shelf 310. Other embodiments, however, also exist. For instance, another advantageous embodiment exists wherein the mounting flange 350 is mounted at a mid point of the shelf 310. In this embodiment, the shelf 310 would extend out past a front plane of the component rack when the shelf 310 is mounted therein. This advantageous embodiment allows for easier access to the components held by the shelf 310.

Turning now briefly to FIG. 5, illustrated is a sectional view of the support mechanism 300 illustrated in FIG. 4 taken through the line 5-5. As illustrated in FIG. 5, the unique design of the present invention only reduces a shelf space of the shelf 310 by a distance X, wherein the distance X consists of the thickness of the sidewall 320, thickness of the mounting flange 350 and distance that the slot 330 extends from the sidewall 320. Accordingly, the distance X need not account for the thickness of a nut, nor the safety threads, as the prior art structures did. Accordingly, a considerable amount more shelf space is available. Moreover, the unique design of the present invention does not require the difficult task of installing the nuts to the fastener, as required by the prior art.

Turning finally to FIG. 6, illustrated is a plan view of a rack of components 600 manufactured and assembled in accordance with the principles of the present invention. The rack of components 600 initially includes a component rack 610. The component rack 610 may comprise a number of different component racks while staying within the scope of the present invention. Nevertheless, in the embodiment of FIG. 6 the component rack 610 comprises a 19″ wide rack capable of containing many support mechanisms 620.

As is illustrated, the support mechanisms 620, each of which may be similar to the support mechanisms 300 illustrated in FIGS. 3-5, are coupled to the component rack 610 at vertically spaced positions. Additionally located within the support mechanisms 620 are one or more conventional components 630. In an exemplary embodiment, the one or more conventional components 630 are chosen from the group consisting of rectifiers, converters, ringers, distributions, controllers, fans, baffles, trays, or combinations thereof. It goes without saying, however, that the present invention should not be limited to any specific component 630.

Although the present invention has been described in detail, those skilled in the art should understand that they can make various changes, substitutions and alterations herein without departing from the spirit and scope of the invention in its broadest form. 

1. A support mechanism for holding a component in a component rack, comprising; a shelf configured to hold a component, the shelf having a sidewall with at least two slots therein extending from the sidewall and the shelf; and a mounting flange couplable to the shelf, the mounting flange having at least two tabs configured to engage the at least two slots.
 2. The support mechanism as recited in claim 1 wherein the at least two tabs are configured to engage the at least two slots and substantially fix all but one axis of movement with respect to eachother.
 3. The support mechanism as recited in claim 2 wherein the at least two slots contain an opening through a face thereof for accepting a fastener.
 4. The support mechanism as recited in claim 3 wherein the at least two tabs contain a threaded opening configured to removably mate with threads of the fastener and thereby secure the one axis of movement.
 5. The support mechanism as recited in claim 1 wherein the at least two tabs are flush with opposing faces of the mounting flange.
 6. The support mechanism as recited in claim 1 wherein the at least two slots extend outwardly from the sidewall and the shelf.
 7. The support mechanism as recited in claim 1 wherein the mounting flange has at least three tabs configured to engage three slots extending from the sidewall and the shelf.
 8. The support mechanism as recited in claim 1 wherein the shelf has slots located along an entire length of the sidewall, and wherein the at least two tabs are configured to engage consecutive slots.
 9. The support mechanism as recited in claim 8 wherein the slots located along the entire length of the sidewall have predetermined and different spacings.
 10. The support mechanism as recited in claim 9 wherein the predetermined and different spacings correlate to predetermined and different spacings of the at least two tabs and establish a position of the mounting flange with respect to the shelf.
 11. The support mechanism as recited in claim 1 wherein the mounting flange is configured to mount substantially flush with a front surface of the shelf.
 12. The support mechanism as recited in claim 1 wherein the mounting flange is configured to mount at a mid point of the shelf.
 13. The support mechanism as recited in claim 1 wherein the mounting flange has an ear extending substantially perpendicular to a surface that the at least two tabs are located on, and wherein the ear is configured to fasten the mounting flange to a vertical position along a component rack.
 14. The support mechanism as recited in claim 1 wherein the mounting flange is a first mounting flange and further including a second mounting flange coupleable to the shelf, the second mounting flange having at least two tabs configured to engage at least two slots extending from a second opposing sidewall of the shelf.
 15. A method for manufacturing a support mechanism for holding a component in a component rack, comprising; providing a shelf configured to hold a component, the shelf having a sidewall with at least two slots therein extending from the sidewall and the shelf; and creating a mounting flange coupleable to the shelf, the mounting flange having at least two tabs configured to engage the at least two slots.
 16. The method as recited in claim 15 wherein the at least two tabs are configured to engage the at least two slots and substantially fix all but one axis of movement with respect to eachother.
 17. The method as recited in claim 16 wherein the at least two slots contain an opening through a face thereof for accepting a fastener.
 18. The method as recited in claim 17 wherein the at least two tabs contain a threaded opening configured to removably mate with threads of the fastener and thereby secure the one axis of movement.
 19. The method as recited in claim 15 wherein the slots are created by punching the sidewall and the tabs are created by stamping the flange.
 20. The method as recited in claim 15 wherein the at least two slots extend outwardly from the sidewall and the shelf.
 21. A rack of components, comprising; a component rack; a plurality of support mechanisms coupled to the component rack at vertically spaced positions, each support mechanism comprising; a shelf configured to hold a component, the shelf having a sidewall with at least two slots therein extending from the sidewall and the shelf; and a mounting flange coupled to the shelf, the mounting flange having at least two tabs engaging the at least two slots and an ear extending substantially perpendicular to a surface that the at least two tabs are located on, and wherein the ear fastens the flange and shelf to a vertical position along the component rack; and one or more components located in the support mechanisms.
 22. The rack of components as recited in claim 21 wherein the at least two tabs are configured to engage the at least two slots and substantially fix all but one axis of movement with respect to eachother.
 23. The rack of components as recited in claim 22 wherein the at least two slots contain an opening through a face thereof for accepting a fastener.
 24. The rack of components as recited in claim 23 wherein the at least two tabs contain a threaded opening configured to removably mate with threads of the fastener and thereby secure the one axis of movement.
 25. The rack of components as recited in claim 21 wherein the at least two slots extend outwardly from the sidewall and the shelf.
 26. The rack of components as recited in claim 21 wherein the mounting flange is a first mounting flange and further including a second mounting flange coupled to a second opposing sidewall of the shelf, the second mounting flange having at least two tabs configured to engage at least two slots extending from the second opposing sidewall and having a second ear extending substantially perpendicular to a surface that the at least two tabs of the second opposing sidewall are located on, and wherein the second ear fastens the second flange and further fastens the shelf to the vertical position along the component rack.
 27. The rack of components as recited in claim 21 wherein the one or more components are one or more components selected from the group of components consisting of: rectifiers; converters; ringers; distributions; controllers; fans; baffles trays; and combinations thereof. 